It is true, despite the fact that it has become something of an old saw, that logistics is understudied. The general public, businesses, and even government regulators have a tendency to pay little attention to the specifics of how goods get from point A to point B. There are many pages in Title 21 of the Code of Federal Regulations for Food and Drugs that are devoted to the application and licensing of drugs, in addition to requirements for paperwork, manufacturing, and labeling. It provides very little guidance on the requirements and design of pharmaceutical warehouses, and it offers only one suggestion for warehouse layout, which specifies that pharmaceutical warehouses should operate on a first-in, first-out basis to prevent drugs from expiring while they are stored.
Pharmaceutical companies and their logistics managers are largely left to their own devices when it comes to the design of a pharmaceutical warehouse, as well as the development of practices for storage and retrieval of pharmaceutical products. They are responsible for adhering to best practices for the handling of pharmaceuticals and designing warehouses that can store and deliver pharmaceuticals in an accurate and safe manner. Unfortunately, logistics managers are frequently forced to make do with aging facilities and equipment that aren’t up to par with the demands of the job. However, there are compelling reasons for making sure that the layout, automation, and equipment used in your pharmaceutical warehouse are chosen with care and are kept up to date.
Organizing and Planning an Effective Layout for a Pharmaceutical Warehouse
The layout of a warehouse is extremely important to the smooth running of the business. Because of the characteristics of their products, pharmaceutical companies face a unique set of challenges when designing the layouts of their warehouses and distribution centers. Not only are pharmaceuticals susceptible to contamination from the outside, such as bacteria or chemicals, but they are also sensitive to changes in temperature. In some instances, pharmaceuticals can be harmed by exposure to even lighting. Additionally, pharmaceuticals need to be stored in a manner that facilitates the use of a first-in, first-out system, protects these essential and pricey products from being intentionally tampered with or stolen, and makes it simple to use a first-in, first-out system. Because of these specific requirements, there are a number of considerations that need to be taken into account when establishing a warehouse for the storage of pharmaceuticals.
For a warehouse that deals with pharmaceutical warehousing, the through warehouse configuration is likely to be the more effective choice when compared to the other two warehouse layouts.
There are essentially two distinct varieties of warehouse workflow patterns to choose from. A circular or “U-shape” warehouse pattern is set up to allow traffic to flow around the storage areas in the center, with input and output occurring through the same entrance/exit. A “through” pattern directs incoming pharmaceutical inventories into one side of the warehouse and out the opposite side. A “through” pattern also directs outgoing pharmaceutical inventories into the opposite side of the warehouse. In both of these configurations, the products with the highest demand are stocked in the area immediately adjacent to the loading dock, while the products with the lower demand are kept further away from the loading docks. Items that are in high demand are stored in a warehouse known as a “through” warehouse, which organizes their inventory so that the items with the lowest demand are located closer to the building’s exterior walls. Items with a high frequency of demand are stocked closer to the loading bays in a warehouse organized in a “U-pattern,” while items with a lower frequency of demand are stocked further away from the doors. The items with the lowest demand are positioned against the back wall. Every one of these configurations comes with its own set of benefits and drawbacks:
Through the Utilization of Warehouse Benefits:
- In a linear design, products only move in one direction, making it simpler to monitor compliance with a first-in, first-out shipping schedule. This is because there is only one path that products can take.
- Multiple Channels The throughput of the warehouse can be easily divided into multiple channels, each of which flow in the same direction. This reduces the likelihood that an employee will select the incorrect item.
Discrete Temperature Areas: Various lines of throughput can be designated as temperature-controlled areas or cold storage areas without interfering with one another in any way. Discrete temperature areas are also referred to as temperature zones.
Advantages of Using a Circular Warehouse
Combined Trips Because the forklift will be returning to the same location, it is possible to send it out on a single trip to retrieve inventory and put away a load at the same time.
Products that arrive at the loading dock have the ability to be immediately shipped out without having to be put away, and without requiring a fork truck to make a special trip in the event that a rush order is placed. This practice is known as cross-docking.
Enhanced Space Control Because there is only one entrance and exit to the warehouse, it is much simpler to keep track of the product’s security, as well as the internal temperature and atmosphere.
For a warehouse that deals with pharmaceuticals, the through warehouse configuration is likely to be the more effective choice when compared to the other two warehouse layouts. The requirement that first-in, first-out shipping be built into the design from the beginning, and having a linear product flow makes it easy to organize and pick items accurately. On the other hand, through-type warehouses are not a particularly common layout. They call for access roads to be built at both the input and output ends of the warehouse, whereas the vast majority of warehouses are designed with only one entry point. Nevertheless, depending on how the items are stored and retrieved, linear throughput may be achieved within the warehouse even if it has an irregular external shape.
To Meet the Requirements of a Pharmaceutical Warehouse with the Help of Equipment and Automation
One strategy for making the layout of your warehouse more efficient is to install pallet racks. Pallet racks maximize the amount of inventory that can be stored in your warehouse because they increase the efficiency with which the space is utilized. Warehouses that store pharmaceutical products can completely eliminate aisles by combining these racks with something called a pallet mole, which is also known as a pallet shuttle. The operation of this form of automation is entirely conducted in a linear fashion, and it is relatively easy and inexpensive to implement.
When using a pallet mole system, the very first load that is placed in the racks is also the very first load that is chosen to be shipped.
A pallet mole is a straightforward machine that travels along a track and is designed to lift pallets from below and move them along a row in a rack to the following available slot. It then moves back to the input position after delivering the pallet to the destination. When using a pallet mole system, the very first load that is placed in the racks is also the very first load that is chosen to be shipped. Because of this, pharmaceutical warehouses that make use of pallet moles will, in effect, have created a “through” warehouse regardless of the external layout of the facility. Additionally, this system combines many of the benefits that are offered by the two primary warehouse layouts by providing:
Discrete Channels: Each row in a pallet rack can be used for a designated pharmaceutical. This makes it possible to have a multichannel warehouse with a reduced risk of workers performing tasks that are intended for different channels.
Temperature Zones: Each temperature zone can have its own pallet rack and shuttle system, which will bring maximized volumes and efficient linear flow to all areas of the warehouse.
Combined Movements: A single forklift can be instructed to move product from one side of a U-shaped layout into a storage system and then pick product from the output side of the layout.
Because linear movement is restricted to the storage and retrieval areas of the warehouse in this layout, and the facility maintains a single loading and unloading point, it is possible to cross-dock while also maintaining a higher level of control over the safety of the warehouse. A pallet rack that also includes a pallet mole brings together the most beneficial aspects of both of these types of warehouse configurations.
The dependability of plastic is essential to ensuring that the automation process continues uninterrupted and without causing any damage to the products being manufactured.
It does, however, have one great disadvantage. If there is a problem deep within the racks, it can be time-consuming and expensive to remove all of the product from the affected channels, fix the issue, and then replace the items. To put it another way, if you want to get the most out of supply chain automation, you need to make sure to only use equipment that is sturdy and dependable.
Warehouse automation necessitates the use of plastic pallets because of this reason. Plastic shipping platforms, in contrast to those made of wood, have consistent weights, dimensions, and strengths. The dependability of plastic is essential to ensuring that the automation process continues uninterrupted and without causing any damage to the products being manufactured. Before being put to use, plastic pallets can also be washed and sanitized, which helps to keep pharmaceuticals and the supply chain equipment that handles them, such as racks and pallet moles, free from contamination. Plastic pallets can also be recycled. The requirements for pharmaceutical warehouses may be determined primarily by the pharmaceutical companies themselves; however, if those companies use plastic pallets, they have the ability to set a very high bar.
